Methylene beta-diketone monomers, methods for making methylene beta-diketone monomers, polymerizable compositions and products formed therefrom

ABSTRACT

The present teachings are directed at 1,1-disubstituted alkene monomers (e.g., methylene beta-diketone monomers), methods for producing the same, and compositions and products formed therefrom. In the method for producing the monomer, a beta-diketone is preferably reacted with a source of formaldehyde in a modified Knoevenagel reaction optionally in the presence of an acidic or basic catalyst, and optionally in the presence of an acidic or non-acidic solvent, to form reaction complex. The reaction complex may be an oligomeric complex. The reaction complex is subjected to vaporization in order to isolate the monomer. The monomer(s) may be employed in compositions and products, including monomer-based products (e.g., inks, adhesives, coatings, sealants or reactive molding) and polymer-based products (e.g., fibers, films, sheets, medical polymers, composite polymers and surfactants).

CLAIM OF PRIORITY

This application is a continuation-in-part and claims priority to U.S.patent applications Ser. No. 14/352,369 filed on Apr. 17, 2014, Ser. No.14/075,334 filed on Nov. 8, 2013, and Ser. No. 14/810,741 filed on Jul.28, 2015, the contents of each of which in their entirety are herebyincorporated herein by reference. U.S. patent application Ser. No.14/352,369 is a 35 U.S.C. §371 National Phase Application ofInternational PCT Patent Application PCT/US2012/060840, filed on Oct.18, 2012, which application claims the benefit of priority to U.S.Provisional Patent Applications 61/549,104, filed on Oct. 19, 2011,61/549,092, filed on Oct. 19, 2011, and 61/549,152 filed on Oct. 19,2011, the contents of each of which in their entirety are herebyincorporated herein by reference. U.S. patent application Ser. No.14/075,334 is a continuation of U.S. patent application Ser. No.13/880,438, filed on Jul. 22, 2013 which is a U.S. National Stageapplication under 35 U.S.C. §371 of International Patent ApplicationPCT/US2011/056903, filed Oct. 19, 2011, which International PatentApplication claims the benefit of priority of U.S. Provisional PatentApplications 61/405,029, filed Oct. 20, 2010, 61/405,049, filed Oct. 20,2010, 61/405,078, filed Oct. 20, 2010, 61/405,033, filed Oct. 20, 2010,61/405,056, filed Oct. 20, 2010, 61/523,311, filed Aug. 13, 2011, and61/523,705, filed Aug. 15, 2011, the disclosures of each of which areexpressly incorporated by reference in their entireties. U.S. patentapplication Ser. No. 14/810,741 claims priority to U.S. patentapplication Ser. No. 14/789,178 filed on Jul. 1, 2015 and U.S.Provisional Patent Applications 62/186,479 filed on Jun. 30, 2015,62/182,076 filed on Jun. 19, 2015, 62/047,283 filed on Sep. 8, 2015, and62/047,328 filed on Sep. 8, 2015, the contents of each of which in theirentirety are hereby incorporated herein by reference.

INCORPORATION BY REFERENCE

All documents cited or referenced herein and all documents cited orreferenced in the herein cited documents, together with anymanufacturer's instructions, descriptions, product specifications, andproduct sheets for any products mentioned herein or in any documentincorporated by reference herein, are hereby incorporated by reference,and may be employed in the practice of the invention.

FIELD OF THE INVENTION

The invention relates to a new class of methylene beta-diketonemonomers, to methods of producing or synthesizing such monomers, and tothe use and application of such monomers as commercial products andcompositions, including, for example, monomer-based products (e.g.,inks, adhesives, coatings, sealants or reactive molding) andpolymer-based products (e.g., fibers, films, sheets, medical polymers,composite polymers and surfactants).

The new monomers relate to a platform of methylene beta-diketonemonomers having the general structural formula:

Products produced with such monomers include, for example, polymerizablecompositions and polymers formed therefrom, e.g., inks, adhesives,coatings, sealants, reactive moldings, fibers, films, sheets, medicalpolymers, composite polymers and surfactants.

BACKGROUND

Methylene malonate monomers have been disclosed for example in U.S. Pat.Nos. 2,313,501; 2,330,033; 3,221,745; 3,523,097; 3,557,185; 3,758,550;3,975,422; 4,049,698; 4,056,543; 4,160,864; 4,931,584; 5,142,098;5,550,172; 6,106,807; 6,211,273; 6,245,933; 6,420,468; 6,440,461;6,512,023; 6,610,078; 6,699,928; 6,750,298; and Patent Publications2004/0076601; WO/2012/054616A2; WO2012/054633A2.

While various earlier methods for producing methylene malonates havebeen known for many years, these prior methods suffer significantdeficiencies which preclude their use in obtaining commercially viablemonomers. Such deficiencies include unwanted polymerization of themonomers during synthesis (e.g., formation of polymers or oligomers oralternative complexes), formation of undesirable side products (e.g.,ketals or other latent acid-forming species which impede rapidpolymerization), degradation of the product, insufficient and/or lowyields, and ineffective and/or poorly functioning monomer product (e.g.,poor adhesive characteristics, stability, or other functionalcharacteristics), among other problems. The overall poorer yield,quality, and chemical performance of the monomer products formed byprior methods has impinged on their practical use in the production ofthe above commercial and industrial products. No viable solutions tosolve the aforementioned problems have yet been proposed, acceptedand/or recognized and certainly do not exist currently in the industry.

For example, in U.S. Pat. No. 2,330,033 to Gaetano D'Alelio (“the '033patent”), methylene malonic esters are prepared by condensing a malonicester with formaldehyde under alkaline conditions, acidifying withacetic acid and dehydrating the mass and distilling the methylenemalonic ester. In each example of the '033 patent, the condensationreaction is acidified using acetic acid. Furthermore, the ester isdescribed as polymerizing spontaneously in the absence of inhibitors.Thus, the reaction conditions described in the '033 patent would haveled to the undesirable premature polymerization of the monomer and theproduction of deleterious side products. Further, the reference does noteven recognize the formation of such deleterious side products, letalone does it provide any teachings or suggestions as to how to avoid oreliminate the formation of these impurities. Accordingly, the methylenemalonates purportedly formed by this process are impractical for use inthe production of viable commercial and industrial products.

Similarly, in U.S. Pat. No. 2,313,501 to Bachman et al. (“the '501patent”), methylene dialkyl malonates are prepared by the reaction ofdialkyl malonates with formaldehyde in the presence of an alkali metalsalt of a carboxylic acid in a substantially anhydrous carboxylic acidsolvent. The method of the '501 patent purports to provide higher yieldsthan the prior methods of condensing formaldehyde with a dialkylmalonate in the presence of a base. In the '501 patent, methylenediethyl malonate is distilled directly from the reaction mixture undersub-atmospheric pressure. The ester is described as forming a soft waxywhite polymer upon standing, indicating the presence of a high degree ofdeleterious side products. The '501 patent does not even recognize theformation of such deleterious side products, let alone does it provideany teachings or suggestions as to how to avoid or eliminate theformation of such impurities. Thus, the methylene malonates purportedlyformed by this process are highly unstable and are impractical for usein the production of viable commercial and industrial products.

Furthermore, in U.S. Pat. No. 3,197,318 to Halpern et al. (“the '318patent”), dialkyl methylene malonic acid esters are prepared bycondensing dimethylmalonate with formaldehyde in the presence of aceticacid and an acetate of a heavy metal at 100-110° C. The reaction mixtureis directly distilled under reduced pressure. The '318 patent statesthat in the anhydrous composition, the reaction either fails to occur oris greatly delayed by the inhibitor up to the time when theeffectiveness of the inhibitor is reduced by contact of moisturetherewith (from occluded surface water on glass, metal or the like). Theunfavorable reaction conditions described in this reference would haveled to the production of deleterious side products. The '318 patent doesnot even recognize the formation or presence of these impurities, letalone offer teachings or suggestions as to how to avoid or eliminatetheir formation. Accordingly, the methylene malonates purportedly formedby the process of the '318 patent would have been impractical for theiruse in the production of viable commercial products.

Also, in U.S. Pat. No. 3,221,745 to Coover et al. (“the '745 patent”),monomeric dialkyl esters of methylene malonic acid are purportedlyprepared in high purity because even with small amounts of impuritiesthat influence polymerization the adhesive utility will be impaired. The'745 patent describes removing all impurities to levels below 100parts-per-million preferably below 10 parts-per-million. The monomersare prepared by hydrogenating the olefinic bond of a dialkylalkoxy-methylenemalonate in the presence of a hydrogenation catalyst andpyrolyzing the reaction product. The '745 patent states that these highpurity materials polymerize and form firm bonds in situ rapidly, withinseconds. Indeed, the '745 patent, like related U.S. Pat. No. 3,523,097to Coover et al. (“the '097 patent”), requires the use of an acidicstabilizer to enhance shelf-life and to prevent prematurepolymerization. However, the high temperature conditions of thepyrolysis reaction invariably results in the formation of unwanted anddeleterious side products and is a much more expensive and difficultsynthesis process for preparing methylene malonate as compared to theKnovenagel reaction with formaldehyde. Thus, the monomer purportedlyformed by the processes of the '745 and '097 patents is impractical foruse in the production of viable commercial and industrial products.

Still further, in U.S. Pat. No. 3,758,550 to Eck et al. (“the 550patent”) report on a general process for producing methylene malonicesters of the general formula CH₂═C(—CO₂R)₂, by reactingparaformaldehyde in glacial acetic acid in the presence of a catalyst toform a product in the form of a “gel” which is then “cracked ” at hightemperature distillation. The reaction is conducted over long periods oftime, including up to 15 hours, and produces a substantial amount ofdeleterious side products, as evidenced by the gelatinouscharacteristics of the product. Further, the '550 patent contains nosupport showing the functionality of the monomers produced. Due to thelikely presence of high levels of impurities, the functionality of themonomers produced by the '550 patent would likely be substantiallycompromised.

Citing numerous disadvantages of the foregoing processes, whichdisadvantages were said to make them difficult, if not impossible, toprovide commercially viable monomers, Bru-Magniez et. al. (U.S. Pat. No.4,932,584 and U.S. Pat. No. 5,142,098) (“the '584 and '098 patents”)developed a process whereby anthracene adducts were prepared by reactingmono- or di-malonic acid ester with formaldehyde in the presence ofanthracene, most preferably in a non-aqueous solvent medium in thepresence of select catalysts. According to these patents, the anthraceneadducts were said to be readily produced in high yields with the desiredmethylene malonates obtained by stripping them from the anthraceneadduct by any of the known methods including heat treatment,thermolysis, pyrolysis or hydrolysis; preferably heat treatment in thepresence of maleic anhydride. The resultant crude products were thensubjected to multiple distillations, preferably lower temperaturedistillations under vacuum, to recover the purified methylene malonates.Despite the claim to high yields, their crude yields were generally inthe range of 21-71%, and more importantly, nothing is taught withrespect to the purity of the material obtained.

While the use of intermediate adducts promoted higher yields and allowedgreater versatility, particularly with respect to the broader variety ofmethylene malonates capable of being produced, lingering problemspersisted, namely batch-to-batch inconsistency and the generalinstability of the process as well as the so-formed crude and finalproducts, especially in bulk storage, and of formulated products, suchas adhesives, made with the same. Additionally, the adduct routesinvolve considerable added expense, particularly in light of the needfor the additional reactants and other materials, added production stepsand time, new energy requirements and environmental concerns, and thelike. Furthermore, despite their advances, these processes have yet tofully or even adequately address, particularly from a commercialviability standpoint, the underlying and critical problems evidenced bythe continuing inconsistency in the production of the methylidenemalonates, particularly as reflected by the ongoing instability of thereaction mix particularly during the distillation and recovery of thedesired product as well as of the recovered product. It is this erraticnature of the production process and resultant product and the attendantcosts associated therewith that compromises and overshadows thecommercial value and opportunity for these products.

Similar conclusions may be drawn from other representative priorreferences that purport to teach the synthesis of methylene malonates,including, for example, U.S. Pat. Nos. 3,557,185; 3,975,422; 4,049,698;4,056,543; 4,160,864; and 6,106,807. None of these references, however,recognize the same problems discussed above, including the formation ofdeleterious side products, such as, ketals and other latent acid-formingspecies which impede monomer performance, the occurrence of unwantedpolymerization (e.g., unintended formation of polymers, oligomers oralternative complexes) and the general degradation and instability ofthe monomer products which together substantially impedes the productionof high-quality methylene malonate monomers having commercial viability.

In view of the above art, there remains no known single viablecommercially suitable method or process for the chemical synthesis ofmethylene malonate monomers which may be utilized to produce theseimportant raw materials for the generation of a wide variety ofcommercial and industrial products. Thus, a need exists for improvedmethods for synthesizing methylene malonate monomers that are capable ofbeing viably used in commercial and industrial applications.

The present invention solves the aforementioned problems in thesynthesis of methylene malonate monomers and paves the way to acommercially viable source of an important raw material.

Free radical polymerization of dialkyl methylene malonate monomers usingheat, UV light and peroxide is described in U.S. Pat. Nos. 2,330,033 and2,403,791, both incorporated herein by reference. In these patents, themonomer was prepared using traditional methods which results in lowpurity monomer. The polymer examples in these patents are all preparedvia bulk polymerization. One would therefore not expect to be able tocontrol polymer properties, such as molecular weight and molecularweight distribution.

As described in certain of those publications, methylene malonates havethe potential to form the basis of a large-scale platform of rawmaterials useful in a wide variety of chemical products.

It is envisioned that methylene beta-diketone monomers and theirassociated monomeric and polymeric-based products would be useful inindustrial, consumer, and medical applications. Specifically, methylenebeta-diketone monomers would provide a benefit over other monomers inthat the incorporation of a ketone group adjacent to the activemethylene group reduces the susceptibility of degradation of the monomerupon utilization or further functionalization. Indeed, unlike many othermonomers, methylene beta-diketone monomers and their products can beproduced via sustainable routes as well as be designed to beenvironmentally benign, biologically benign and as such many of theproducts can be generally regarded as “green.”

Thus, there exists a need in the art for methods of synthesizing novelmethylene beta-diketone monomers, formulating novel polymerizablecompositions, and providing polymer products based on this platform.

SUMMARY OF THE INVENTION

The purpose and advantages of the present invention will be set forth inand apparent from the description that follows. Additional advantages ofthe invention will be realized and attained by the methods and systemsparticularly pointed out in the written description and claims hereof,as well as from the appended drawings.

In one aspect, the invention provides a methylene beta-diketone monomerhas a structure:

wherein R₁ and R₂ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl,halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl),heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C1-C15 alkyl),heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-C15 alkyl), eachof which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl,heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl,C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy,carboxy, or ester;

or

wherein R₁ and R₂ are taken together with the atoms to which they arebound to form a 5-7 membered heterocyclic ring which may be optionallysubstituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl,halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl),aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio,hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester.

In another aspect, the invention provides a method of making a methylenebeta-diketone monomer comprising:

-   -   a) reacting a beta-diketone reactant having the structural        formula:

-   -   under suitable reaction conditions for sufficient time with a        source of formaldehyde, optionally in the presence of an acidic        or basic catalyst, and optionally in the presence of an acidic        or non-acidic solvent, to form a reaction complex; and    -   b) isolating a methylene beta-diketone monomer from the reaction        complex, wherein the methylene beta-diketone monomer has the        structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₁₅ alkyl,C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), oralkoxy-(C1-15 alkyl), each of which may be optionally substituted byC₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl,nitro, azido, cyano, acyloxy, carboxy, or ester;

or

wherein R₁ and R₂ are taken together with the atoms to which they arebound to form a 5-7 membered heterocyclic ring which may be optionallysubstituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl,halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl),aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio,hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester.

In certain embodiments, the methods of the invention herein include thestep of isolating the methylene beta-diketone by:

-   -   i. contacting the reaction complex, or a portion thereof, with        an energy transfer means to produce a vapor phase including the        methylene beta-diketone monomer; and    -   ii. collecting the methylene beta-diketone monomer from the        vapor phase.

In other embodiments, the methods of the invention herein includeisolating the methylene beta-diketone by:

-   -   i. heating the reaction complex, or a portion thereof, to a        temperature between about 130° C. and about 300° C. to produce a        vapor phase including the methylene beta-diketone monomer; and    -   ii. collecting the methylene beta-diketone monomer from the        vapor phase.

In still other embodiments, the methods of the invention are performedunder reaction conditions of:

-   -   a) an initiating temperature of between about 60° C. and about        130° C.;    -   b) atmospheric pressure.

In another aspect, the invention provides a method of preparing amethylene beta-diketone monomer comprising:

-   -   a) reacting a beta-diketone reactant having the structural        formula:

-   -   under suitable reaction conditions for sufficient time with a        source of formaldehyde, optionally in the presence of an acidic        or basic catalyst, and optionally in the presence of an acidic        or non-acidic solvent, to form a reaction complex;    -   b) contacting the reaction complex, or a portion thereof, with        an energy transfer means at a temperature between about 150° C.        and about 300° C. to provide the reaction complex, or portion        thereof, as a vapor phase; and    -   c) isolating a methylene beta-diketone monomer from the reaction        complex or portion thereof, wherein the methylene beta-diketone        monomer has the structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₁₅ alkyl,C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), oralkoxy-(C1-15 alkyl), each of which may be optionally substituted byC₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl,nitro, azido, cyano, acyloxy, carboxy, or ester;

or

wherein each instance of R₁ and R₂ are taken together with the atoms towhich they are bound to form a 5-7 membered heterocyclic ring which maybe optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅alkylthio, hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester.

In another aspect, the invention provides a polymerizable compositioncomprising a methylene beta-diketone monomer of the invention.

In certain embodiments, the polymerizable composition is capable ofbonding glass to a substrate in a time period of less than about 90seconds, less than about 60 seconds, less than about 30 seconds, or lessthan about 15 seconds.

In certain other embodiments, the polymerizable composition comprising amethylene beta-diketone monomer further comprises at least one additiveselected from the group consisting of an acidic stabilizer, a freeradical stabilizer, a sequestering agent, a cure accelerator, a rheologymodifier, a plasticizing agent, a thixotropic agents, a natural rubber,a synthetic rubbers, a filler agent and a reinforcing agent.

In another aspect, the invention provides an adhesive product comprisinga methylene beta-diketone monomer of the invention.

In certain embodiments, the adhesive products have a shelf life of atleast one year.

In another aspect, the invention provides a polymer formed bypolymerization of one or more methylene beta-diketone monomers or apolymerizable composition thereof.

In certain embodiments, the polymers of the invention are useful as asealant, a coating, a textile fiber, a water-treatment polymer, an inkcarrier, a paint carrier, a packaging film, a molding, a medicalpolymer, a polymer film, a polymer fiber, or a polymer sheet.

In certain other embodiments, the polymers of the invention have repeatunits of the formula:

wherein R and R′ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl,halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl),heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl-(C1-C15 alkyl),heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-15 alkyl), eachof which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl,heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl,C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy,carboxy, or ester.

In another aspect, the invention provides an oligomeric complex preparedby reacting a beta-diketone with a source of formaldehyde; optionally inthe presence of heat transfer agent; optionally in the presence of anacidic or basic catalyst; and optionally in the presence of an acidic ornon-acidic solvent. In certain embodiments, the oligomeric complex hasbetween 2 and 12 repeat units having the structural formula:

wherein R and R′ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl,halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl),heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl-(C1-C15 alkyl),heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-15 alkyl), eachof which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl,heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl,C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy,carboxy, or ester.

In still another aspect, the invention provides a methylenebeta-diketone monomer prepared according to the methods of theinvention.

The invention may include a step of minimizing the recovery of volatilelatent acid forming impurities. This step may in certain embodimentscomprise (a) adding to the reaction mixture water and an acid having apKa range of −8 to 5; (b) adding to the reaction mixture a stericallyhindered organic acid; or (c) adding to the reaction mixture anon-volatile organic acid, or any combination of (a), (b) or (c). Incertain other embodiments, the step of minimizing the recovery ofvolatile latent acid forming impurities may comprise adding to thereaction mixture water and an acid having a pKa range of −8 to 5.

The methylene beta-diketone monomers (e.g., the methylene malonatemonomers) may be used to make products, including but not limited to, anadhesive, a coating, a sealant, a composite, or a surfactant. Suchproducts, in various embodiments, can further comprise an acidicstabilizer, a free radical stabilizer, a sequestering agent, a cureaccelerator, a rheology modifier, a plasticizing agent, a thixotropicagents, a natural rubber, a synthetic rubbers, a filler agent, areinforcing agent or a combination thereof.

In certain embodiments, the acid stabilizer can have a pKa in the rangeof −15 to 5, or in the range of −15 to 3, or in the range of −15 to 1.

In some embodiments, the acid stabilizer is a volatile acid stabilizerwith a boiling point less than 200° C.

In other embodiments, the acid stabilizer is a volatile acid stabilizerwith a boiling point less than 170° C.

In still other embodiments, the acid stabilizer is a volatile acidstabilizer with a boiling point less than 130° C.

In other embodiments, the acid stabilizer can be an acidic gas, such as,for example, SO₂ or BF₃.

In some embodiments, the acid stabilizer can be present in aconcentration of about 0.1 ppm to about 100 ppm, or from about 0.1 ppmto about 50 ppm, or from about 0.1 ppm to about 25 ppm, or from about0.1 ppm to about 15 ppm.

The methylene beta-diketone monomers and/or products (e.g., themethylene malonate monomers and/or products) may include a free radicalstabilizer, such as a phenolic free radical stabilizer, and may bepresent in a concentration of about 0.1 ppm to about 10000 ppm, or fromabout 0.1 ppm to about 3000 ppm, or from about 0.1 ppm to about 1500ppm, or from about 0.1 ppm to about 1000 ppm, or from about 0.1 ppm toabout 300 ppm, or from about 0.1 ppm to about 150 ppm.

In yet another embodiment, the present invention relates to an adhesiveproduct or composition comprising a methylene malonate monomer preparedaccording to a method of the invention and which is stable for at leastone year.

In other embodiments, the monomer and/or the polymerizable compositions(e.g., the adhesive products formed by a method of the invention), arecompositions wherein the level of ketals is less than about 100 ppm, orless than about 50 ppm, or less than about 25 ppm, or less than about 10ppm, or less than about 5 ppm, or even less than about 0.1 ppm, or less.

In still other embodiments, the monomer and/or the polymerizablecomposition (e.g., the adhesive products formed by a method of theinvention), have a purity such that the level of other latentacid-forming impurities is less than about 100 ppm, or less than about50 ppm, or less than about 25 ppm, or less than about 10 ppm, or lessthan about 5 ppm, or even less than about 0.1 ppm, or less.

Another aspect of the disclosure is directed at a process comprising thesteps of: mixing one or more monomers (including a first monomer that isa 1,1-disubstituted alkene compound (e.g., a methylene beta-diketonemonomer)) and a solvent; adding an activator; reacting the activatorwith one of the one or more monomers (e.g., with the first monomer) forinitiating the anionic polymerization of the one or more monomers; andanionically polymerizing the one or more monomers to form a polymerhaving a weight average molecular weight and/or a number averagemolecular weight of about 2000 daltons or more, the polymer includingthe first monomer, wherein the first monomer is provided as a highpurity monomer having a purity of about 95 weight percent or more.Preferably the high purity monomer has a purity of about 97 weightpercent, even more preferably about 99 weight percent. For example, thehigh purity monomer may include the 1,1-disubstituted alkene compoundhaving an alkene group and the total concentration of any analogouscompound (i.e., impurity compound) having the alkene group replaced byhydroxyalkyl group is about 3 mole percent or less (preferably about 1mole percent or less, even more preferably about 0.1 mole percent orless, and most preferably about 0.01 mole percent or less), based on thetotal moles of the 1,1-disubstituted alkene compound. The 1,1,disubstituted alkene compound may be a methylene beta-diketone monomer.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the subjectinvention pertains will more readily understand how to make and use theinvention as described herein, preferred embodiments thereof will bedescribed in detail below, with reference to the drawings, wherein:

FIGS. 1 and 2 depict NMR spectra demonstrating evidence of a methylenediketone reaction product formed by the reaction of5,5-dimethylhexane-2,4-dione and formaldehyde.

FIG. 3 depicts an NMR spectrum demonstrating evidence of a methylenediketone reaction product formed by the reaction of heptane-3,5-dionewith formaldehyde.

FIG. 4 depicts an NMR spectrum demonstrating evidence of a methylenebeta-diketone reaction product formed by the reaction of5-methylhexane-2,4-dione with formaldehyde.

FIGS. 5 and 6 depict NMR spectra demonstrating evidence of a methylenediketone reaction product formed by the reaction of1-phenylbutane-1,3-dione with formaldehyde.

FIG. 7 depicts an NMR spectrum demonstrating evidence of a methylenediketone reaction product formed by the reaction of1,3-diphenylpropane-1,3-dione with formaldehyde.

FIGS. 8 and 9 depict NMR spectra demonstrating evidence of a methylenediketone reaction product formed by the reaction of nonane-4,6-dionewith formaldehyde.

DETAILED DESCRIPTION OF THE INVENTION

Overview

The present invention provides new and nonobvious improvements andmodifications in the use and application of the Knoevenagel reaction inorder to produce methylene beta-diketone monomers:

While the above reaction scheme shows a direct condensation reaction, ithas been discovered that an intermediary species (oligomeric complex)may be formed in certain instances. The oligomeric complex may then becracked to yield the monomer product. As those having skill in the artwill appreciate, the reaction scheme may also yield side reactions andundesired products, and unreacted starting material from which themethylene beta-diketone monomers are subsequently isolated.

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the meaning commonly understood by a person skilled in the art towhich this invention belongs. The following references provide one ofskill with a general definition of many of the terms used in thisinvention: Singleton et al., Dictionary of Microbiology and MolecularBiology (2nd ed. 1994); The Cambridge Dictionary of Science andTechnology (Walker ed., 1988); The Glossary of Genetics, 5th Ed., R.Rieger et al. (eds.), Springer Verlag (1991); and Hale & Marham, TheHarper Collins Dictionary of Biology (1991). As used herein, thefollowing terms have the meanings ascribed to them below, unlessspecified otherwise.

As used herein, the term “methylene beta-diketone monomer” refers to acompound having the core formula —C(O)—C(═CH₂)—C(O)—.

As used here, the term “beta-diketone” refers to a compound having thecore formula —C(O)—CH₂—C(O)—.

As used herein, the term “reaction complex” refers to the materialswhich result after reacting a beta-diketone starting material with asource of formaldehyde. Such reaction complexes may comprise, withoutlimitation, methylene beta-diketone monomers, oligomeric complexes,irreversible complex impurities, starting materials, or latentacid-forming impurities.

As used herein, the term “reaction vessel” refers to any container inwhich the reactants, solvents, catalysts or other materials may becombined for reaction. Such reaction vessels can be made of any materialknown to one of skill in the art such as metal, ceramic or glass.

As used herein, the term “vapor phase” refers to a gaseous phase whichmay comprise, without limitation, vaporized methylene beta-diketonemonomer, vaporized starting materials; vaporized solvents, or vaporizedimpurities.

As used herein, the term “recovering” or “obtaining” or “isolating”refers to the removal of the monomer from the reaction mixture, vaporphase, or condensed vapor phase by one of the methods described herein,although the desired product may not be in a purified form. The term“crack” is also used to indicate depolymerization of an oligomericcomplex. The desired methylene beta-diketone monomer may be obtained by“cracking” an oligomeric complex found in the reaction complex.

As used herein, the term “sterically hindered” refers to a compound inwhich the size of groups within the molecule prevents chemical reactionsthat are observed in related smaller molecules.

As used herein, the terms “volatile” and “non-volatile” refers to acompound which is capable of evaporating readily at normal temperaturesand pressures, in the case of volatile; or which is not capable ofevaporating readily at normal temperatures and pressures, in the case ofnon-volatile.

As used herein, the term “energy transfer means” refers to a means whichis capable of volatizing a reaction complex, usually by, but not limitedto, rapidly heating the reaction complex to temperatures from about 150°C. to about 300° C. Such energy transfer means include, but are notlimited to, heat transfer agents, heat transfer surfaces, lasers, andsources of radiation.

As used herein, the term “heat transfer agent” refers to a materialwhich is capable of achieving a high temperature and transferring thattemperature to a reaction mixture. Such heat transfer agents aretypically able to reach temperatures from about 150° C. to about 300° C.and include, but are note limited to silica, silicone oil, mineral oil,a petroleum based heat transfer oil or a synthetic chemical based heattransfer oil. In certain embodiments, the heat transfer agent can bepre-formed reaction complex.

As used herein the term “pre-formed reaction complex” refers to areaction complex as defined herein which is prepared by reacting step(a) as described herein in advance of the vaporization step (b). Suchpre-formed reaction complexes can be formed up to a year, up to sixmonths, up to 3 months, up to 1 month, up to 2 weeks, up to 1 week, upto 3 days, or up to 1 day in advance of the vaporization step (b). Insuch instances, the vaporization step (b) is performed on a newlyprepared reaction complex. In certain aspects the pre-formed reactioncomplex can refer to an oligomeric complex as defined herein.

As used herein the term “substantial absence” as in “substantial absenceof acidic solvent” refers to a reaction mixture comprising less than 1%by weight of the particular component as compared to the total reactionmixture. In certain embodiments, a “substantial absence” refers to lessthan 0.7%, less than 0.5%, less than 0.4%m less than 0.3%, less than0.2% or less than 0.1% by weight of the of the particular component ascompared to the total reaction mixture. In certain other embodiments, a“substantial absence” refers to less than 1.0%, less than 0.7%, lessthan 0.5%, less than 0.4% m less than 0.3%, less than 0.2% or less than0.1% by volume of the of the particular component as compared to thetotal reaction mixture.

As used herein, the term “stabilized,” e.g., in the context of“stabilized” molecules of the invention or compositions comprising same,refers to the tendency of the molecules of the invention (or theircompositions) to substantially not polymerize with time, tosubstantially not harden, form a gel, thicken, or otherwise increase inviscosity with time, and/or to substantially show minimal loss in curespeed (i.e., cure speed is maintained) with time.

As used herein, the term “shelf-life,” e.g., as in the context of themolecules of the invention having an improved “shelf-life,” refers tothe molecules of the invention which are stabilized for a given periodof time, e.g., 1 month, 6 months, or even 1 year or more.

As used herein, the term “latent acid-forming impurities” or “latentacid-forming impurity” refers to any impurity that, if present alongwith the recovered methylene malonate monomer, will with time beconverted to an acid. The acid formed from these impurities tends toresult in overstabilization of the monomer (e.g., methylenebeta-diketone monomer or methylene malonate monomer), thereby reducingthe overall quality and reactivity of the monomer.

As used herein, the term “ketal” refers to molecule having a ketalfunctionality; i.e. a or molecule containing a carbon bonded to two —ORgroups, where O is oxygen and R represents any alkyl group.

Description of Exemplary Embodiments

Methylene beta-diketone monomers in accordance with the presentinvention may be made by a modified Knoevenagel condensation reaction ofa beta-diketone with formaldehyde under suitable reaction conditions.The general reaction scheme is provided below.

Methylene Beta-Diketone Monomers

In one aspect, the invention provides a methylene beta-diketone monomerhaving the structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₁₅ alkyl,C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), oralkoxy-(C1-15 alkyl), each of which may be optionally substituted byC₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl,nitro, azido, cyano, acyloxy, carboxy, or ester;

-   or-   wherein R₁ and R₂ are taken together with the atoms to which they    are bound to form a 5-7 membered heterocyclic ring which may be    optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆    cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl,    heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl,    C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano,    acyloxy, carboxy, or ester.

In certain embodiments, the invention provides a methylene beta-diketonemonomer having the structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₆ alkyl,halo-(C₁-C₆ alkyl), C₃-C₆ cycloalkyl, aryl, or heteroaryl, each of whichmay be optionally substituted by halo or C₁-C₆ alkoxy.

In still other embodiments, the invention provides a methylenebeta-diketone monomer having the structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₆ alkyl oraryl.

Reactants

The reaction for making methylene beta-diketone monomers of theinvention includes at least two basic reactants: a beta-diketoneprecursor and a source of formaldehyde.

In certain embodiments, the methylene beta-diketone precursors inaccordance with exemplary embodiments disclosed herein includebeta-diketones able to undergo a condensation reaction at the alphacarbon. Beta-diketone precursors include, but are not limited to,molecules having the structural formula:

wherein each instance of R₁ and R₂ are independently C₁-C₁₅ alkyl,C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), oralkoxy-(C1-15 alkyl), each of which may be optionally substituted byC₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl—(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl,nitro, azido, cyano, acyloxy, carboxy, or ester;

or

wherein R₁ and R₂ are taken together with the atoms to which they arebound to form a 5-7 membered heterocyclic ring which may be optionallysubstituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl,halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl),aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio,hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester.

In certain other embodiments, the present invention contemplates thefollowing specifically identified beta-diketone precursors:1,3-dimethyl-propane-1,3-diones, 1,3-diethyl-propane-1,3-diones,1-ethyl-3-methyl-propane-1,3-diones, 1,3-dipropyl-propane-1,3-diones,1,3-dibutyl-propane-1,3-diones, and 1,3-diphenyl-propane-1,3-diones,among others.

The beta-diketone precursor may be derived or obtained from any source,including any commercial source, derived from nature, other compounds,synthesized by other processes, etc. In certain embodiments, thebeta-diketone precursors are obtained from “green” sources. For example,the beta-diketone precursors can be derived from biological sources,such as via fermentation production systems whereby microorganismsgenerate the beta-diketone precursors is direct metabolic by-products offermentation—or whereby the microorganisms generate metabolicby-products of fermentation that can be then converted inexpensively tothe desired beta-diketone precursors. These fermentation productionsystems are well-known in the art and may utilize either—orboth—microorganisms derived from nature or engineered microorganismsthat are specifically designed to produce the desired beta-diketoneprecursors products, e.g., recombinant or engineered Escherichia coli.

The beta-diketone precursor is reacted with a source of formaldehyde.The methods of the invention also contemplate any suitable source offormaldehyde. For example, the formaldehyde may be synthesized, derivedfrom another chemical species (e.g., paraformaldehyde), or obtained fromnature or from some other suitable source. In certain embodiments, theformaldehyde is introduced in the form of a gas. Commercial sources offormaldehyde and paraformaldehyde are readily available, which mayinclude, for example, trioxane and formalin (e.g., aqueousformaldehyde). The source of formaldehyde may be paraformaldehyde,formalin, trioxane or gaseous formaldehyde. In certain embodiments, theformaldehyde is obtained from paraformaldehyde. In an exemplaryembodiment, the source of formaldehyde is paraformaldehyde that isthermally degraded to formaldehyde in the reaction vessel. It isenvisioned that other means of providing formaldehyde to the reactionvessel may be utilized, for example, a stream of gaseous formaldehyde.

Catalysts

In certain embodiments, the methods of preparing the methylenebeta-diketone takes place in the presence of a suitable catalyst.However, it is envisioned that certain reactions may not required thepresence of a catalyst.

In certain embodiments, the catalysts that may be used include, but arenot limited to, basic catalysts such as potassium acetate, sodiumacetate, zinc acetate, zinc diacetate dihydrate, aluminum acetate,calcium acetate, magnesium acetate, magnesium oxide, copper acetate,lithium acetate, aluminum oxide, or zinc oxide.

In further embodiments, the catalysts include, but are not limited to,acidic catalysts such as paratoluene sulfonic acid, dodecylbenzenesulfonic acid, boron trifluoride, zinc perchlorate, sulfated zirconiumoxide, sulfated titanium oxide, lithium chloride, boron trifluorideetherate, ferric sulfate, zirconium oxychloride, cupric chloride,titanium tetrachloride, or zinc chloride.

Still other exemplary catalysts are heterogeneous catalysts. Still otherexemplary catalysts are enzyme catalysts. An exemplary enzyme isNovozym® 435 available from Novozyme. Novozym 435 is an immobilizedgranulate, non-specific lipase particularly useful for ester production.Neutral catalysts can also include silica and other insolublesurface-active agents.

In still further embodiments, amphoteric catalysts can include, but arenot limited to, aluminum oxide, aluminum acetate, zinc acetate,magnesium acetate, and zinc oxide.

In still other embodiments, the present inventors have surprisingly andunexpectedly found that no catalyst is required to conduct the synthesisreaction of the invention. Specifically, in this embodiment, thereaction can be conducted with all of the reactants added to thereaction vessel at the start of the reaction prior to adding heat. Thesource of formaldehyde in this embodiment is preferably solidparaformaldehyde, and is added along with the other reactants, includingthe malonic ester, prior to adding heat. This reaction surprisingly canbe run rapidly and in a continuous mode and unexpectedly avoids theformation of—or substantially minimizes the formation of—deleteriousside products, unwanted polymerization complexes and degradation of themonomer products.

Solvents

The present invention contemplates that the synthesis reaction includesan acidic or non-acidic solvent, or optionally no solvent at all.

Non-acidic solvents can include, but are not limited to,tetrahydrofuran, chloroform, dichloromethane, toluene, heptane, ethylacetate, n-butyl acetate, dibutyl ether and hexane.

Acidic solvents can include, but are not limited to acetic acid andpropionic acid.

In certain embodiments, the acidic solvent is added just prior torecovery.

In certain other embodiment, optionally no solvent is needed. Thiszero-solvent approach will not only decrease the overall cost ofproduction but will also help to lessen any negative impact on theenvironment caused by the methods of the invention, i.e., provides anenvironmentally-friendly approach to the synthesis of2-methylene-1,3-disubstituted-propane-1,3-diones. An advantage of thiscondition is the avoidance or minimization of the formation ofimpurities, e.g., ketals and other latent acid-forming species.

In still other embodiments, the present inventors have surprisingly andunexpectedly found that the synthesis reaction of the invention may beconducted in the absence of both a solvent and a catalyst. Specifically,in this embodiment, the reaction can be conducted with all of thereactants added to the reaction vessel at the start of the reactionprior to adding heat and in the absence of a solvent. The source offormaldehyde in this embodiment is preferably solid paraformaldehyde,and is added along with the other reactants, including the malonicester, prior to adding heat. This reaction surprisingly can be runrapidly and in a continuous mode and unexpectedly avoids the formationof—or substantially minimizes the formation of—deleterious sideproducts, unwanted polymerization complexes and degradation of themonomer products.

The formation of the monomer may be carried out with a step ofminimizing the recovery of volatile latent acid forming impurities fromthe reaction complex, such as ketals, which can co-distill with the1,1-disubstituted alkene monomer (e.g., methylene beta-diketone monomeror methylene malonate monomer) products and then revert to their acidicform with time. Once in their acidic form, the acidic environmentincreases, which further blocks or weakens the reactivity of the1,1-disubstituted alkene monomer as they are stabilized againstpolymerization. This can be particularly relevant to the use of1,1-disubstituted alkene monomers in the context of adhesives, where theincreased acid content with time due to the presence of such volatilelatent acid forming impurities can impinge on the overall reactivity andcure speed, etc., of the monomer products.

Although the invention may employ an improved Knovenagel reaction withformaldehyde to synthesize 1,1-disubstituted alkene monomer (e.g.,methylene beta-diketone monomer or methylene malonate monomer), thepresent invention should not be limited as such. The present inventorshave generally recognized it is believed for the first time generalconcept that the performance and overall quality of 1,1-disubstitutedalkene monomer (e.g., methylene beta-diketone monomer or methylenemalonate monomer) is particularly sensitive to the presence of unwantedalternative and deleterious side products and unwanted monomerdegradation and/or consumption is widely applicable to any type ofsynthesis that can be used to generate 1,1-disubstituted alkene monomer.Prior to the present invention, the significance and nature of thesetypes of impurities and their effects on the performance and quality ofmethylene malonates was not previously contemplated. Thus, for the firsttime, the present invention provides a viable approach to producing1,1-disubstituted alkene monomer(s) that can be utilized as the basisfor viable consumer and industrial monomer-based (e.g., adhesives) andpolymer-based (e.g., fibers) products.

The 1,1-disubstituted alkene compound (e.g., the methylene beta-diketonecompound) preferably is prepared using a method which results in asufficiently high purity so that it can be polymerized. The purity ofthe 1,1-disubstituted alkene compound(e.g., the methylene beta-diketonecompound) may be sufficiently high so that 70 mole percent or more,preferably 80 mole percent or more, more preferably 90 mole percent ormore, even more preferably 95 mole percent or more, and most preferably99 mole percent or more of the 1,1-disubstituted alkene compound isconverted to polymer during a polymerization process. The purity of the1,1-disubstituted alkene compound (e.g., the methylene beta-diketonecompound) preferably is about 85 mole percent or more, more preferablyabout 90 mole percent or more, even more preferably about 93 molepercent or more, even more preferably about 95 mole percent or more,even more preferably about 97 mole percent or more, and most preferablyabout 99 mole percent or more, based on the total weight of the1,1-disubstituted alkene compound. If the 1,1-disubstitute alkenecompound includes impurities, preferably about 40 mole percent or more,more preferably about 50 mole percent or more of the impurity moleculesare the analogous 1,1-disubstited alkane compound. The concentration ofany impurities having a dioxane group preferably is about 2 mole percentor less, more preferably about 1 mole percent or less, even morepreferably about 0.2 mole percent or less, and most preferably about0.05 mole percent or less, based on the total weight of the1,1-disubstituted alkene compound. The total concentration of anyimpurity having the alkene group replaced by an analogous hydroxyalkylgroup (e.g., by a Michael addition of the alkene with water), preferablyis about 3 mole percent or less, more preferably about 1 mole percent orless, even more preferably about 0.1 mole percent or less, and mostpreferably about 0.01 mole percent or less, based on the total moles inthe 1,1-disubstituted alkene compound. Preferred 1,1-disubstitutedalkene compounds are prepared by a process including one or more (e.g.,two or more) steps of distilling a reaction product or an intermediatereaction product (e.g., a reaction product or intermediate reactionproduct of a source of formaldehyde and a malonic acid ester).

The 1,1-disubstituted alkene compound (e.g., the methylene beta-diketonecompound) may include a monomer produced according to the teachings ofU.S. Pat. No. 8,609,885 (Malofsky et al.) incorporated herein byreference in its entirety. Other examples of monomers which may beemployed include the monomers taught in International Patent ApplicationPublication Nos. WO2013/066629 and WO 2013/059473, both incorporatedherein by reference.

Stabilization

Certain embodiments of the present invention provide monomers that areamenable to anionic polymerization. Therefore, to prevent unwantedpolymerization and extend shelf life, certain exemplary embodimentsinclude suitable acidic stabilizers, for example, trifluoromethanesulfonic acid, maleic acid, methane sulfonic acid, difluoro acetic acid,trichloroacetic acid, phosphoric acid, dichloroacetic acid,chlorodifluoro or like acid. Acidic stabilizers can include any materialwhich can be added to the monomer or polymer compositions to extendshelf-life, e.g., by up to, for example, 1 year or more. Such acidicstabilizers may have a pKa in the range of, for example, between about−15 to about 5, or between about −15 to about 3, or between about −15 toabout 1, or between −2 to about between about −2 to about 2, or betweenabout 2 to about 5, or between about 3 to about 5.

Reaction Conditions

In certain embodiments of the present invention, the starting precursoris reacted with paraformaldehyde in the presence of a catalyst (e.g.,zinc acetate dehydrate) at 60° C.-130° C. (e.g., 100° C.) for at leastabout 30 minutes. The resulting intermediate material (e.g., oligomericcomplex) is then thermally depolymerized to the vinyl containing productby addition to a hot surface set from 150° C. to 270° C. The resultingcrude monomer is then purified, for example by distillation, fractionaldistillation or other separation methods.

For a typical lab scale reaction: a 3-neck 250 mL round bottom reactionflask was equipped with an overhead stirrer, a heating mantle, and atemperature probe connected to a temperature controller. The reactionflask was adequately vented to the back of the hood to reduce thepossibility of pressure build-up. The beta-diketone (precursor),paraformaldehyde (1.8 equiv) and zinc acetate (0.001 equiv) were addedto the reaction flask. The contents of the flask were mixed forapproximately 2 minutes prior to the application of heat. After theinitial mixing period the temperature controller was set to 100° C. Theheterogeneous reaction mixture was allowed to heat with the temperaturefor dissolution and onset of exotherm being noted. Once a rapid increasein temperature was observed, heating was discontinued. Once the exothermsubsided, the heating mantle was immediately removed and the reactionmixture (herein “reaction complex”) was allowed to cool to roomtemperature to afford the oligomeric mixture.

To isolate the methylene beta-diketone monomer from the reactioncomplex, a 4-neck suitable round bottom flask was equipped with amechanical stirrer, heating mantle, a thermocouple connected to atemperature controller, an addition funnel, a Claisen adapter, and avacuum adapter connected to a receiver one-neck round bottom flask whichwas placed in an ice-bath. The system was evacuated to low pressure(1-250 mmHg). The oligomeric mixture was added to the addition funnel.The reaction flask was then applied via the connected heating mantle to150-270° C. Once the temperature inside the flask reached the desiredrange, a drop-wise addition of the oligomer (reaction complex) toreaction flask was started. The addition rate was maintained so that theset temperature was maintained in the desired range. After the additionwas complete, the heating mantle was turned off and the system wasallowed to cool to room temperature, at this point the system was openedto atmospheric pressure. An aliquot was then taken for analysis and theremaining cracked distillate was either distilled further via fractionaldistillation to improve purity or placed in a refrigerator.

This general reaction scheme was utilized to provide the examplesprovided herein. Due to the wide variety of example obtained, it isenvisioned that this general reaction scheme can be utilized to providea wide array of methylene beta-diketone monomers as set forth herein.Further, it is envisioned that modifications can be made to this generalreaction scheme in order to improve efficiencies and purity of theproduct obtained.

Methods of Synthesis

In another aspect, the invention provides a method of preparingmethylene beta-diketone monomers according to the reaction schemedisclosed herein.

In certain embodiments, the method for preparing the methylenebeta-diketone monomers comprises:

-   -   a) reacting a beta-diketone reactant having the structural        formula:

-   -   under suitable reaction conditions for sufficient time with a        source of formaldehyde, optionally in the presence of an acidic        or basic catalyst, and optionally in the presence of an acidic        or non-acidic solvent, to form a reaction complex; and    -   b) isolating a methylene beta-diketone monomer from the reaction        complex, wherein the methylene beta-diketone monomer has the        structural formula:

wherein R₁ and R₂ are defined above.

In certain embodiments, the reaction may be initiated at temperaturesbetween about 60° C. to about 130° C., at atmospheric pressure. It iscontemplated that the reaction conditions may be modified depending onthe source of formaldehyde. For example, when paraformaldehyde isutilized within the reaction vessel, the initial temperature must behigh enough to make free formaldehyde available for the reaction. Ifanother source of formaldehyde is utilized, those having skill in theart will appreciate that the reaction conditions may be modifiedaccordingly. Exemplary sources include paraformaldehyde, formalin,trioxane, gaseous formaldehyde, or any reaction or process in whichformaldehyde is liberated.

In other embodiments, the methylene beta-diketone monomer may beisolated from the reaction complex by contacting the reaction complex,or a portion thereof, with an energy transfer means to produce a vaporphase including the methylene beta-diketone monomer; and collecting themethylene beta-diketone monomer from the vapor phase.

In still other embodiments, the methylene beta-diketone monomer may beisolated from the reaction complex immediately, or the reaction complexmay be stored, preferably refrigerated, until a later time. In anexemplary embodiment, the reaction complex is not acid stabilized priorto isolating the methylene beta-diketone monomer.

In other embodiments, the reaction complex, or a portion thereof, may beheated to a vapor phase and condensed in order to isolate the methylenebeta-diketone monomer. The reaction complex may be heated to atemperature between about 130° C. and about 300° C.

In still other embodiments, the reaction complex, or a portion thereof,may come in contact with an energy transfer means in order to facilitateisolation of the monomer. In an exemplary embodiment, the reactioncomplex, or portion thereof, may be vaporized in a very short time, forexample less than 15 minutes, preferably less than 1 minute, morepreferably less than 30 seconds, and less than 1 second. Certainexemplary embodiments contemplate vaporizing the reaction complex in acontinuous manner as it is formed during the reaction step.

Exemplary energy transfer means include a heat transfer agent, a heatexchanger, a laser, microwave energy, sonic energy, electromagneticenergy, and a source of radiation, or any combination thereof. Theenergy transfer means operates to quickly vaporize the reaction complex(or portion thereof) to permit isolation of the monomer product. Forexample, an oligomeric complex may be formed, and the energy transfermeans is utilized to “crack” or depolymerize the oligomer to allowisolation of the monomer. In certain embodiments, the oligomeric complexmay include oligomers of 2-12 units able to provide monomer product uponcrack.

In certain exemplary embodiments, the heat transfer agent is a heatedinert gas, one or more metal beads, one or more glass beads, one or moreporcelain beads, sand, silica, silicone oil, mineral oil, a petroleumbased heat transfer oil, a synthetic chemical based heat transfer oil,or a pre-formed portion of the reaction complex.

In certain other embodiments, the heat exchanger is a shell and tubeheat exchanger, a plate heat exchanger, and adiabatic wheel heatexchanger, a finned pipe heat exchanger, a plate fin heat exchanger, ora scraped surface heat exchanger.

In still other embodiments, the vapor phase of the reaction complex iscondensed, and the condensate is subject to one or more furtherseparation processes. For example, the separation process may includeany of simple distillation, fractional distillation, flash distillation,steam distillation, vacuum distillation, short path distillation,thin-film distillation, reactive distillation, pervaporation, extractivedistillation, flash evaporation, rotary evaporation, liquid/liquidextraction, centrifuging, or any combination thereof, and othertechniques known to those having skill in the art.

Compositions

The methylene beta-diketone monomers of the invention can beincorporated into any number of compositions and products including butnot limited to reactive monomer-based compositions, reactiveoligomer-based compositions and reactive polymer-based compositions.

Exemplary compositions can be analyzed by placing a drop of a monomercomposition on a substrate (for example a glass slide or 4″×1″polycarbonate sample). Another glass slide or piece of polycarbonate ispressed on top over the monomer-covered area. The time is thenimmediately recorded from pressing the top-slide till the two slides arebonded tightly. In such embodiments, the exemplary composition iscapable of bonding glass to a substrate in less than about 90 seconds,less than about 60 seconds, less than about 30 seconds or less thanabout 15 seconds. Similarly, the exemplary composition is capable ofbonding polycarbonate to a substrate in less than about 90 seconds, lessthan about 60 seconds, less than about 45 seconds or less than about 30seconds.

Alternatively, exemplary compositions can be analyzed by mixing 0.5 mlof monomer with 0.3 ml of 3% tertiary butyl ammonium fluoride (TBAF) inDibutyl Phthalate solution. The time is recorded from adding the TBAFsolution till the mixture become solid with vigorous stirring or mixing.In such embodiments, said composition solidifies upon addition of 3%tertiary butyl ammonium fluoride (TBAF) in Dibutyl Phthalate solution inless than about 15 seconds, less than about 10 seconds, or less thanabout 7 seconds.

Alternatively still, the exemplary compositions can be analyzed byplacing 0.5 ml of monomer into a test tube and cap with a cork stopperand keeping the test tubes containing monomers at 25° C., or in ovens at55° C. or 82° C. In each case the storage stability test is performed atatmospheric pressure. Time is recorded when the monomer became a gel orsolid. In such embodiments, said composition remains stable at 25° C.and at atmospheric pressure for more than 10 days, more than 15 days,more than 20 days, more than 25 days or more than 30 days. Similarly,said composition remains stable at 82° C. and at atmospheric pressurefor more than about 2 hours, more than about 3 hours, or more than about4 hours.

Exemplary compositions include, but are not limited to an adhesive, acoating, a sealant, a composite, or a surfactant.

Additionally polymer products include, but are not limited to, asealant, a thermal barrier coating, a textile fiber, a water-treatmentpolymer, an ink carrier, a paint carrier, a packaging film, a molding, amedical polymer, a polymer film, a polymer fiber or a polymer sheet.

In each case, the exemplary compositions may be formulated to includeone or more materials to extend the shelf-life as well as control theonset of cure of the materials. In certain embodiments, the compositionsare formulated such that the composition is stable for at least 1 month,or for at least 2 months, or for at least 3 months, or for at least 4months, or for at least 5 months, or for at least 5-10 months, or for atleast 10-20 months, or for at least 20-30 months. Preferably, theadhesive composition comprising the methylene beta-diketone monomers orother commercial compositions or products, are stable for at least oneyear.

Such formulation materials include acidic stabilizer, volatile acidstabilizers, acidic gases, free radical stabilizers, sequesteringagents, cure accelerators and rheology modifiers.

Exemplary embodiments contemplate any suitable acidic stabilizer knownin the art, including, for example, trifluoromethane sulfonic acid,maleic acid, methane sulfonic acid, difluoro acetic acid,trichloroacetic acid, phosphoric acid, dichloroacetic acid,chlorodifluoro or like acid. Acidic stabilizers can include any materialwhich can be added to the monomer or polymer compositions to extendshelf-life, e.g., by up to, for example, 1 year or more. Such acidicstabilizers may have a pKa in the range of, for example, between about−15 to about 5, or between about −15 to about 3, or between about −15 toabout 1, or between −2 to about between about −2 to about 2, or betweenabout 2 to about 5, or between about 3 to about 5.

Volatile acid stabilizers include any material which can be added to themonomer or polymer compositions to extend shelf-life and stabilize thevapor phase above the composition upon storage, e.g., acidic gases. Suchvolatile acid stabilizers may have a boiling point, for example, lessthan about 200° C.; less than about 170° C.; or less than about 130° C.

Acidic gases include any gaseous material which can be added to themonomer or polymer compositions to extend shelf-life and stabilize thevapor phase above the composition upon storage. Such acid gases caninclude, but are not limited to, SO₂ or BF₃.

For each of these acidic stabilizing materials, such acidic stabilizercan be present in a concentration of about 0.1 ppm to about 100 ppm;about 0.1 ppm to about 25 ppm; or about 0.1 ppm to about 15 ppm.

Free radical stabilizers can include any material capable of stabilizingor inhibiting free radical polymerization of the material upon standing.In one embodiment, the free radical stabilizers are phenolic freeradical stabilizers such as, HQ (hydroquinone), MEHQ(methyl-hydroquinone), BHT (butylated hydroxtoluene) and BHA (butylatedhydroxyanisole). In certain embodiments, the free radical stabilizersare present in a concentration of 0.1 ppm to 10,000 ppm; 0.1 ppm to 3000ppm; or 0.1 ppm to 1500 ppm. In certain other embodiments, particularlywhere a free radical or ultraviolet cure will be utilized, the freeradical stabilizers are present in a concentration of 0.1 ppm to 1000ppm; 0.1 ppm to 300 ppm; or 0.1 ppm to 150 ppm.

Sequestering agents include any material capable of enhancing thebonding of materials containing acid salts such as paper or wood. Suchsequestering agents include, but are not limited to crown ethers, silylcrowns, calixarenes and polyethylene glycols. Sequestering agents alsoenhance the utility of surface accelerators that are acid salts appliedto surfaces to control the rate of cure of the materials.

Cure accelerators include any material capable of speeding the rate ofcure of the methylene beta-diketone monomers. Cure accelerators alsoinclude any material capable of speeding the cure through volume of theapplied composition. Such cure accelerators include but are not limitedto sodium or potassium acetate; acrylic, maleic or other acid salts ofsodium, potassium lithium copper and cobalt; salts such as tetrabutylammonium fluoride, chloride, or hydroxide; or chemically basic materialssuch as amines and amides, or salts of polymer bond acids, benzoatesalts, 2,4-pentanedionate salts, sorbate salts, or propionate salts.Such cure accelerators can be added directly to the exemplarycompositions or applied to the material to be bonded prior to additionof the composition.

Rheology modifiers include any material which can modify the viscosityof the exemplary compositions as well as thixotropic properties forgreater utility in certain applications. Rheology modifiers include, butare not limited to, hydroxyethylcellulose, ethyl hydroxyethylcellulose,methylcellulose, polymeric thickeners, pyrogenic silica or a combinationthereof.

In certain embodiments, the exemplary compositions may includetougheners. Such tougheners include, but are not limited to, acrylicrubbers; polyester urethanes; ethylene-vinyl acetates; fluorinatedrubbers; isoprene-acrylonitrile polymers; chlorosulfonatedpolyethylenes; homopolymers of polyvinyl acetate; and reaction productsof the combination of ethylene, methyl acrylate and monomers havingcarboxylic acid cure sites, which once formed are then substantiallyfree of processing aids and anti-oxidants; and combinations thereof. Incertain embodiments, the tougheners include those disclosed in U.S. Pat.No. 4,440,910 (O'Connor), directed to rubber toughened cyanoacrylatecompositions through the use of certain organic polymers as tougheningadditives that are elastomeric, i.e., rubbery, in nature, such asacrylic rubbers; polyester urethanes; ethylene-vinyl acetates;fluorinated rubbers; isoprene-acrylonitrile polymers; chlorosulfonatedpolyethylenes; and homopolymers of polyvinyl acetate. In certainembodiments, the toughener is an elastomeric polymer which is acopolymer of methyl acrylate and ethylene, manufactured by DuPont, underthe name of VAMAC, such as VAMAC N123 and VAMAC B-124. VAMAC N123 andVAMAC B-124 are reported by DuPont to be a master batch ofethylene/acrylic elastomer. In other embodiments, the toughener may bethe DuPont materials called VAMAC B-124, N123, VAMAC G, VAMAC VMX 1012or VCD 6200. In other instances, the toughener may be a rubbertoughening component having (a) reaction products of the combination ofethylene, methyl acrylate and monomers having carboxylic acid curesites, (b) dipolymers of ethylene and methyl acrylate, and combinationsof (a) and (b), which once the reaction products and/or dipolymers areformed are then substantially free of processing aids, such as therelease agents octadecyl amine (reported by DuPont to be availablecommercially from Akzo Nobel under the tradename ARMEEN 18D), complexorganic phosphate esters (reported by DuPont to be availablecommercially from R.T. Vanderbilt Co., Inc. under the tradename VANFREVAM), stearic acid and/or polyethylene glycol ether wax, andanti-oxidants, such as substituted diphenyl amine (reported by DuPont tobe available commercially from Uniroyal Chemical under the tradenameNAUGARD 445). Commercial examples of such rubber tougheners includeVAMAC VMX 1012 and VCD 6200 rubbers, and these may be used too.

The exemplary compositions containing methylene beta-diketone monomermay also optionally include other additives, such as plasticizingagents, thixotropic agents, natural or synthetic rubbers, filler agents,and reinforcing agents, etc. Such additives are well known to thoseskilled in the art.

The exemplary compositions containing methylene beta-diketone monomermay optionally include at least one plasticizing agent that impartsflexibility to the polymer formed from the methylene beta-diketonemonomer. The plasticizing agent preferably contains little or nomoisture and should not significantly affect the stability orpolymerization of the monomer. Such plasticizers are useful inpolymerized compositions to be used in any application in whichflexibility of the adhesive or polymer product is desirable.

Examples of suitable plasticizers include, without limitation, acetyltributyl citrate, dimethyl sebacate, triethyl phosphate,tri(2-ethylhexyl)phosphate, tri (p-cresyl)phosphate, glyceryltriacetate, glyceryl tributyrate, diethyl sebacate, dioctyl adipate,isopropyl myristate, butyl stearate, lauric acid, trioctyl trimellitate,dioctyl glutarate, and mixtures thereof. Preferred plasticizers aretributyl citrate and acetyl tributyl citrate. In embodiments, suitableplasticizers include polymeric plasticizers, such as polyethylene glycol(PEG) esters and capped PEG esters or ethers, polyester glutarates andpolyester adipates.

The addition of plasticizing agents in amounts less than about 60 weight%, or less than about 50 weight %, or less than about 30 weight %, orless than about 10 weight %, or less than about 5 weight %, or less thanabout 1 weight % or less, provides increased film strength (e.g.,toughness) of the polymerized monomer over polymerized monomers nothaving plasticizing agents.

The exemplary compositions containing methylene beta-diketone monomermay also optionally include at least one thixotropic agent, i.e., theproperty of exhibiting a high fluidity during deformation by force of asprayer, roller or trowel, but losing the fluidity when left at rest.Suitable thixotropic agents are known to the skilled artisan andinclude, but are not limited to, silica gels such as those treated witha silyl isocyanate. Examples of suitable thixotropic agents aredisclosed in, for example, U.S. Pat. Nos. 4,720,513 or 4,510,273, thedisclosures of which are hereby incorporated in their entireties.

The exemplary compositions containing methylene beta-diketone monomermay also optionally include at least one natural or synthetic rubber toimpart impact resistance, which is preferable especially for industrialcompositions of the present invention. Suitable rubbers are known to theskilled artisan. Such rubbers include, but are not limited to, dienes,styrenes, acrylonitriles, and mixtures thereof. Examples of suitablerubbers are disclosed in, for example, U.S. Pat. Nos. 4,313,865 and4,560,723, the disclosures of which are hereby incorporated in theirentireties.

The exemplary compositions containing methylene beta-diketone monomermay also optionally comprise one or more other reinforcing agents (e.g.,fibrous reinforcements) other than natural or synthetic rubber to impartimpact resistance and/or to impart structural strength or to provideshape or form. Examples of such agents are well known in the art.Examples of suitable fibrous reinforcement include PGA microfibrils,collagen microfibrils, cellulosic microfibrils, and olefinicmicrofibrils. The compositions may also contain colorants such as dyes,pigments, and pigment dyes. Examples of suitable colorants include6-hydroxy-5-[(4-sulfophenyl)axo]-2-naphthalene-sulfonic acid (FD+CYellow No. 6);9-(o-carboxyphenyl)-6-hydroxy-2,4,5,7-tetraiodo-3H-xanthen-3-onemonohydrate (FD+C Red No. 3); and2-(1,3-dihydro-3-oxo-5-sulfo-2H-indol-2-ylidene)-2,3-dihydro-3-oxo-1H-indole-5-sulfonicacid (FD+C Blue No. 2), wherein the suitable colorant should notdestabilize the monomer.

The exemplary compositions containing methylene beta-diketone monomermay also optionally include at least one thickening agent. Suitablethickeners include, for example, polycyanoacrylates, polylactic acid,poly-1,4-dioxa-2-one, polyoxalates, polyglycolic acid, lactic-glycolicacid copolymers, polycaprolactone, lactic acid-caprolactone copolymers,poly-3-hydroxybutyric acid, polyorthoesters, polyalkyl acrylates,copolymers of alkylacrylate and vinyl acetate, polyalkyl methacrylates,and copolymers of alkyl methacrylates and butadiene. Examples of alkylmethacrylates and acrylates are poly(2-ethylhexyl methacrylate) andpoly(2-ethylhexyl acrylate), also poly(butylmethacrylate) andpoly(butylacrylate), also copolymers of various acrylate andmethacrylate monomers, such aspoly(butylmethacrylate-co-methylacrylate).

To improve the cohesive strength of adhesives formed from thecompositions containing methylene beta-diketone monomer, difunctionalmonomeric cross-linking agents may be added to the monomer compositionsof this invention. Such crosslinking agents are known. U.S. Pat. No.3,940,362 to Overhults, which is hereby incorporated in its entirety byreference, discloses such crosslinking agents.

Other compositions and additives contemplated herein, include additionalstabilizers, accelerators, plasticizers, fillers, opacifiers,inhibitors, thixotrophy conferring agents, dyes, fluorescence markers,thermal degradation reducers, adhesion promoters, thermal resistanceconferring agents and combinations thereof, and the like, some of whichare exemplified by U.S. Pat. Nos. 5,624,669; 5,582,834; 5,575,997;5,514,371; 5,514,372; 5,312,864 and 5,259,835, the disclosures of all ofwhich are hereby incorporated in their entirety by reference.

Depending on whether the composition is a monomer-based composition(e.g., inks, adhesives, coatings, sealants or reactive molding) or apolymer-based composition (e.g., fibers, films, sheets, medicalpolymers, composite polymers and surfactants), one having ordinary skillin the art will have the knowledge and skill by which to formulate suchcompositions and/or products without undue experimentation havingsuitable amounts, levels and combinations of the above types ofadditives and components.

Additionally, polymerizable compositions may be formulated to includeadditives such as acidic stabilizers, a free radical stabilizers, asequestering agents, a cure accelerators, rheology modifiers, aplasticizing agents, a thixotropic agents, natural rubbers, syntheticrubbers, filler agents, reinforcing agents and the like. Such additivesare provided at levels sufficient to achieve the desired results whichcan readily be determined by those having skill in the art.

For certain exemplary embodiments, an acidic stabilizer is present in aconcentration of about 0.1 ppm to about 100 ppm, about 0.1 ppm to about25 ppm, or about 0.1 ppm to about 15 ppm, by weight of the composition.

For certain exemplary embodiments, a free radical stabilizer is presentin a concentration selected from about 0.1 ppm to about 10000 ppm, about0.1 ppm to about 3000 ppm, about 0.1 ppm to 1500 ppm, about 0.1 ppm toabout 1000 ppm, about 0.1 ppm to about 300 ppm, or about 0.1 ppm toabout 150 ppm, by weight of the composition.

For certain exemplary embodiments, a sequestering agent, such as a crownether, a silyl crown, a calixarene, a polyethylene glycol, or acombination thereof may be utilized.

For certain exemplary embodiments, a cure accelerator, such as sodiumacetate, potassium acetate, tetrabutyl ammonium fluoride, tetrabutylammonium chloride, tetrabutyl ammonium hydroxide, a benzoate salt, a2,4-pentanedionate salt, a sorbate salt, and a propionate salt, may beutilized.

For certain exemplary embodiments, a rheology modifier, such ashydroxyethylcellulose, ethyl hydroxyethylcellulose, methylcellulose, apolymeric thickener, and pyrogenic silica, may be utilized.

Exemplary polymerizable compositions are stable at 25° C. and atatmospheric pressure for more than 10 days, more than 15 days, more than20 days, more than 25 days, or more than 30 days. Certain exemplaryembodiments may exhibit a shelf life of up to one year, or up to twoyears. Certain exemplary embodiments may be tested for stability atelevated temperature, e.g., 82° C., at atmospheric pressure. Certainexemplary embodiments may exhibit elevated temperature stability formore than 2 hours.

Certain exemplary embodiments disclosed herein relate to polymers andpolymer products formed by polymerization of the polymerizablecompositions comprising the methylene beta-diketone monomers.

Polymers and polymer products envisioned include coatings, paints,fibers, composites, textile fibers, water-treatment polymers, inkcarriers, paint carriers, packaging films, moldings, medical polymers,polymer films, polymer fibers, polymer sheets, and the like. Asdiscussed earlier, the methylene beta-diketone monomers are capable ofsupporting a vast array of products due to the activity of the methylenegroup and the ability to vary the functional groups R, R′ as shown inthe structure of the repeating unit:

wherein R and R′ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl,halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl),heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl-(C1-C15 alkyl),heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-15 alkyl), eachof which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl,heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl,C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy,carboxy, or ester.

Oligomeric Complex Products

The reaction of the precursor beta-diketone with the source offormaldehyde may result in an oligomeric complex which is subsequentlycracked to obtain the desired methylene beta-diketone monomer. Certainoligomeric complexes are capable of being efficiently vaporized or“cracked” into high purity monomers of2-methylene-1,3-disubstituted-propane-1,3-dione by rapid vaporization asdescribed herein.

As such, the invention provides an oligomeric complex prepared byreacting a 1,3-disubstituted-propane-1,3-dione with a source offormaldehyde; optionally in the presence of heat transfer agent;optionally in the presence of an acidic or basic catalyst; andoptionally in the presence of an acidic or non-acidic solvent. Incertain embodiments, the oligomeric complex comprises between 2 and 12repeat units that are able to yield monomer upon cracking.

The invention further provides an oligomeric complex prepared byreacting a 1,3-disubstituted-propane-1,3-dione with a source offormaldehyde in a substantial absence of acidic solvent; optionally inthe presence of heat transfer agent; optionally in the presence of anacidic or basic catalyst; and optionally in the presence of a non-acidicsolvent. In certain embodiments, the substantial absence of acidicsolvent represents less than 1.0%, less than 0.5%, less than 0.2% orless than 0.1% by weight acidic solvent as compared to the totalcomposition of the reaction mixture.

EXAMPLES

The structures, materials, compositions, and methods described hereinare intended to be representative examples of the invention, and it willbe understood that the scope of the invention is not limited by thescope of the examples. Those skilled in the art will recognize that theinvention may be practiced with variations on the disclosed structures,materials, compositions and methods, and such variations are regarded aswithin the ambit of the invention.

Analytical Methods

The structures of monomers of this invention were confirmed using one ormore of the following procedures.

NMR

Samples were diluted in deuterated chloroform prior to 1H NMRspectroscopy at 300 MHz (Bruker). A more concentrated sample was alsoprepared in a solution of 0.01 M Cr(III) acetoacetonate in deuteratedchloroform and was analyzed by quantitative 13C NMR spectroscopy at 75MHz. Samples were not purified.

Abbreviations and Acronyms

A comprehensive list of the abbreviations used by organic chemists ofordinary skill in the art appears in The ACS Style Guide (third edition)or the Guidelines for Authors for the Journal of Organic Chemistry. Theabbreviations contained in said lists, and all abbreviations utilized byorganic chemists of ordinary skill in the art are hereby incorporated byreference. For purposes of this invention, the chemical elements areidentified in accordance with the Periodic Table of the Elements, CASversion, Handbook of Chemistry and Physics, 67th Ed., 1986-87.

More specifically, when the following abbreviations are used throughoutthis disclosure, they have the following meanings:

atm atmosphere

br s broad singlet

C Celsius

d doublet

dd doublet of doublets

MM substituted 3-methylene-2,4-pentanebeta-ketoester

HQ hydroquinone

GC-MS Gas Chromatography-Mass Spectroscopy

g gram

h hour, hours

¹H NMR proton nuclear magnetic resonance

J coupling constant (NMR spectroscopy)

L liter

M mol·L⁻¹ (molar)

m multiplet

MHz megahertz

min minute, minutes

mL milliliter

mM millimolar

mol mole

MS mass spectrum, mass spectroscopy

m/z mass-to-charge ratio

N equivalents·L⁻¹ (normal)

NMR Nuclear Magentic Resonance

pH negative logarithm of hydrogen ion concentration

q quartet

rt room temperature

s singlet

t triplet

RB, RBF round bottom flask

The following concrete examples were made in accordance with the generalreaction scheme set forth above, unless otherwise noted.

Example 1 Reaction of 5,5-dimethylhexane-2,4-dione and Formaldehyde

The reaction scheme disclosed herein was performed using5,5-dimethylhexane-2,4-dione and formaldehyde (obtained fromparaformaldehyde). The following monomer was obtained.

The two small peaks at 5.75 and 6.2 ppm in the 1H spectrum (FIG. 1) andthe peaks at 126 (CH2) and 150 ppm (quaternary) in the 13C spectrum(FIG. 2) are consistent with the geminal CH2 functionality of thedesired structure (below). The DEPT-135 spectrum (FIG. 2) is also shown.

Example 2 Reaction of heptane-3,5-dione and Formaldehyde

The reaction scheme disclosed herein was performed usingheptane-3,5-dione and formaldehyde (obtained from paraformaldehyde). Thefollowing monomer was obtained.

The peak at 6.2 ppm in the ¹H NMR spectrum (FIG. 3) is consistent withthe geminal CH₂ peak of the product:

Example 3 Reaction of 5-methylhexane-2,4-dione and Formaldehyde

The reaction scheme disclosed herein was performed using5-methylhexane-2,4-dione and formaldehyde (obtained fromparaformaldehyde). The following monomer was obtained.

The peaks at 6.2 and 6.3 ppm in the ¹H NMR spectrum in FIG. 4 areconsistent with the geminal CH₂ peak of the product.

Example 4 Reaction of 1-phenylbutane-1,3-dione and Formaldehyde

The reaction scheme disclosed herein was performed using1-phenylbutane-1,3-dione and formaldehyde (obtained fromparaformaldehyde). The following monomer was obtained.

The peaks at 6.1 and 6.6 ppm in the ¹H NMR spectrum of FIG. 5 areconsistent with the geminal CH₂ peak of the product. The peaks at 130ppm (CH2) and 148 ppm (quaternary) in the ¹³C and DEPT-135 NMR spectrain FIG. 6 are also consistent with the product.

Example 5 Reaction of 1,3-diphenylpropane-1,3-dione and Formaldehyde

The reaction scheme disclosed herein was performed using1,3-diphenylpropane-1,3-dione and formaldehyde (obtained fromparaformaldehyde). The following monomer was obtained.

The peak at 6.2 ppm in the ¹H NMR spectrum in FIG. 7 is consistent withthe geminal CH₂ peak of the product shown. The peak at 0 ppm is due tohexamethyldisiloxane, which was added as an internal standard.

Example 6 Reaction of nonane-4,6-dione and Formaldehyde

Potassium tert-butoxide (97.5 g, 0.87 mol) was added to a 1 L 3-neckflask containing 150 mL dry dimethyl formamide and equipped with amechanical stirrer and a thermocouple. The temperature was raised to 50°C. with stirring. Methyl butyrate (200 mL, 1.8 mol) and 2-pentanone (62mL, 0.58 mol) were added as a mixture via 500 mL addition funnel over2.5 h at 50° C. during which the yellow slurry turned to a clear brownsolution. The reaction mixture was stirred for an additional 5 h at 50°C. at which point heating was turned off and the reaction mixture wasallowed to stir for 14 h at room temperature. The reaction mixture wasquenched by slow addition into a 1 M HCl aq. solution (500 mL) at 0° C.,and the pH was adjusted with 1 M HCl aq. solution to about 5. Thereaction slurry was extracted with heptane (4×400 mL). The combinedorganic layers were concentrated to 300 mL under reduced pressure. Theresidue was washed with water (5×400 mL) followed by a brine wash. Theenriched organic layer was further concentrated under reduced pressureto afford a yellowish liquid which was purified by distillation at 65°C., 2 Torr to afford 60 g of 85% pure (based on H NMR analysis) material(56% yield) as a clear liquid.

The following monomer was obtained.

The ¹H NMR spectrum is shown in FIG. 8. The peak at 6.2 ppm isconsistent with the geminal double bond of the product. The 13C andDEPT-135 spectra are shown in FIG. 9. The peak at 129 ppm (CH₂) and at150 ppm (quaternary) are consistent with the geminal double bond of theproduct.

Example 7 Additional Examples

The reaction scheme disclosed herein is performed using an appropriate1,3-disubstituted-propane-1,3-dione and a source formaldehyde to obtainthe following monomers.

Equivalents

Those skilled in the art will recognize, or be able to ascertain usingno more than routine experimentation, many equivalents to the specificembodiments of the invention described herein. Such equivalents areintended to be encompassed by this invention.

What is claimed is:
 1. A polymerizable composition comprising: at least one methylene beta-diketone monomer having the structural formula:

wherein R₁ and R₂ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl-(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-15 alkyl), each of which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester; or wherein R₁ and R₂ are taken together with the atoms to which they are bound to form a 5-7 membered heterocyclic ring which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester; wherein the amount of ketals in the polymerizable composition is less than about 100 ppm and/or the amount of latent acid-forming impurities in the polymerizable composition is less than about 100 ppm.
 2. The polymerizable composition of claim 1, wherein the amount of ketals in the polymerizable composition is less than about 10 ppm and the amount of latent acid-forming impurities in the polymerizable composition is less than about 10 ppm.
 3. The polymerizable composition of claim 1 including a stabilizing amount of at least one stabilizer selected from the group consisting of an acidic stabilizer, a vapor phase stabilizer, and a free radical stabilizer.
 4. The polymerizable composition of claim 3, wherein the polymerizable composition is an adhesive, a coating, or a sealant.
 5. The polymerizable composition of claim 3, wherein the at least one stabilizer includes the acidic stabilizer selected from trifluoromethane sulfonic acid, maleic acid, methane sulfonic acid, difluoro acetic acid, trichloroacetic acid, phosphoric acid, dichloroacetic acid, and chlorodifluoro acid.
 6. The polymerizable composition of claim 3, wherein the at least one stabilizer includes the vapor phase stabilizer selected from hydroquinone, methyl hydroquinone, butylated hydroxytoluene, butylated hydroxyanisole.
 7. The polymerizable composition of claim 1, wherein the methylene beta-diketone monomer is formed as a reaction product of a 1,3-disubstituted-propane-1,3-dione represented by R₁—C(O)—C—C(O)—R₂, and a source of formaldehyde.
 8. The polymerizable composition of claim 7, wherein the 1,3-disubstituted-propane-1,3-dione is selected from the group consisting of 1,3-dimethyl-propane-1,3-diones; 1,3-diethyl-propane-1,3-diones; 1-ethyl-3-methyl-propane-1,3-diones; 1,3-dipropyl-propane-1,3-diones, 1,3-dibutyl-propane-1,3-diones; and 1,3-diphenyl-propane-1,3-diones.
 9. The polymerizable composition of claim 1, wherein the methylene beta-diketone monomer has a structural formula selected from the group consisting of:


10. A polymer prepared from the polymerizable composition of claim
 1. 11. A polymerizable composition comprising: at least one methylene beta-diketone monomer having the structural formula:

wherein R₁ and R₂ are independently C₁-C₁₅ alkyl, C₂-C₁₅ alkenyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl-(C1-C15 alkyl), heteroaryl or heteroaryl-(C₁-C₁₅ alkyl), or alkoxy-(C1-15 alkyl), each of which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester; or wherein R₁ and R₂ are taken together with the atoms to which they are bound to form a 5-7 membered heterocyclic ring which may be optionally substituted by C₁-C₁₅ alkyl, halo-(C₁-C₁₅ alkyl), C₃-C₆ cycloalkyl, halo-(C₃-C₆ cycloalkyl), heterocyclyl, heterocyclyl-(C₁-C₁₅ alkyl), aryl, aryl —(C₁-C₁₅ alkyl), heteroaryl, C₁-C₁₅ alkoxy, C₁-C₁₅ alkylthio, hydroxyl, nitro, azido, cyano, acyloxy, carboxy, or ester; wherein the methylene beta-diketone monomer is a high purity monomer having a purity of about 95 weight percent or more.
 12. The polymerizable composition of claim 11, wherein the amount of any analogous compound having the methylene group of the methylene beta-diketone replaced by a hydroxyaklyl group is about 3 mole percent or less, based on the total moles of the monomer.
 13. The polymerizable composition of claim 12, wherein any impurities in the monomer, if present, includes about 40 mole percent or more of the impurity is an analogous 1,1-disubstituted alkane compound.
 14. The polymerizable composition of claim 11, wherein the concentration of any impurities having a dioxane group is about 2 mole percent or less, based on the total weight of the methylene beta-diketone.
 15. The polymerizable composition of claim 11, wherein the polymerizable composition includes a stabilizing amount of at least one stabilizer selected from the group consisting of an acidic stabilizer, a vapor phase stabilizer, and a free radical stabilizer.
 16. The polymerizable composition of claim 11, wherein the polymerizable composition is an adhesive, a coating, or a sealant.
 17. The polymerizable composition of claim 11, wherein the methylene beta-diketone monomer is formed as a reaction product of a 1,3-disubstituted-propane-1,3-dione represented by R₁—C(O)—C—C(O)—R₂, and a source of formaldehyde.
 18. The polymerizable composition of claim 17, wherein the 1,3-disubstituted-propane-1,3-dione is selected from the group consisting of 1,3-dimethyl-propane-1,3-diones; 1,3-diethyl-propane-1,3-diones; 1-ethyl-3-methyl-propane-1,3-diones; 1,3-dipropyl-propane-1,3-diones, 1,3-dibutyl-propane-1,3-diones; and 1,3-diphenyl-propane-1,3-diones.
 19. The polymerizable composition of claim 11, wherein the methylene beta-diketone monomer has a structural formula selected from the group consisting of:


20. A polymer prepared from the polymerizable composition of claim
 11. 21. A method of preparing a polymerizable composition comprising: forming a methylene beta-diketone monomer by reacting a 1,3-disubstituted-propane-1,3-dione represented by R₁—C(O)—C—C(O)—R₂, and a source of formaldehyde; wherein the reaction product has a purity of about 97 percent or more. 